Methods and apparatus for mobile additive manufacturing

ABSTRACT

The present disclosure provides various aspects for mobile and automated processing utilizing additive manufacturing. The present disclosure includes methods for the utilization of mobile and automated processing apparatus. In some examples, the mobile additive manufacturing apparatus may perform surface treatments that alter the topography of an existing surface. Other examples may involve the processing of dimensionally large layers which may be joined together to create large pieces with three dimensional shape.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority to the U.S. Non-Provisional patentapplication Ser. No. 16/233,439, filed on Dec. 27, 2018 as aContinuation Application, which in turn claims priority to the U.S.Non-Provisional patent application Ser. No. 15/963,767, filed on Apr.26, 2018 as a Continuation Application. The application Ser. No.15/963,767 in turn claims priority to the U.S. Non-Provisional patentapplication Ser. No. 15/641,509, filed on Jul. 5, 2017 as a DivisionalApplication. The application Ser. No. 15/641,509 in turn claims priorityto the U.S. Non-Provisional patent application Ser. No. 14/310,443,filed on Jun. 20, 2014 as a Continuation in Part. The application Ser.No. 14/310,443 in turn claims the benefit of the U.S. ProvisionalApplication Ser. 61/838,302 filed on Jun. 23, 2013. The application Ser.No. 15/561,509 also claims priority to the U.S. Non-Provisional patentapplication Ser. No. 14/310,556, filed on Jun. 20, 2014 as aContinuation in Part. The instant application claims priority to theU.S. Non-Provisional patent application Ser. No. 15/639,766, filed onJun. 30, 2017 as a Continuation in Part. The contents of each are herebyincorporated by reference.

FIELD OF THE INVENTION

The present disclosure relates to methods and apparatus that supportmobile additive material processing. Robotic and human controlledmobility may be combined with additive manufacturing techniques that“print” or additively deliver materials to specific locations oversignificant distances. The methods and apparatus may be applied to theproductions of advanced building structures and roadways.

BACKGROUND OF THE INVENTION

A known class of approaches to material fabrication can be classified asadditive manufacturing. Material in various forms, including solid,powder, gel, gas or liquid forms may be processed in such a manner todeposit or lock in material in a target location in space.

Numerous techniques may be utilized to perform additive manufacturing.In extrusion processes, materials in wire or filament form arecontrolled by an extrusion head which may be moved above a work area.The use of multiple extrusion heads and extrusion material may allow forboth permanent and temporary structures to be formed. By building theextruded material in layers or in regions, complex shapes may be formedin three dimensions. However, the technology is limited by thedimensions of the work space—the ability of the head or heads to move inthe two dimensions of a plane and also by the dimension of the abilityof the head to move vertically relative to a planar support structure.There may be numerous variations on this form of additive manufacturing.

A different class of additive manufacturing may be classified asStereolithography. In this class, a light or heat source is used totransform the material in space. In some Stereolithographyimplementations, the work support plane is submerged in a photoactive orthermo-active liquid and a laser or other light or heat source israstered across a thin surface layer of the liquid between the supportstructure and the top level of the liquid. By translating the supportstructure down a layer into the liquid, the fluent nature of the liquidreforms a thin layer of new unreacted material over the work surface orthe previously processed layer.

Versions of Stereolithography may also work with powder formed startingmaterial. The powder may be shaped into a thin layer and then spatiallydefined. Lasers may be used to transform portions of the layer into asolidified material. In other examples, other energy sources such as,for example, electron beams, may be used to transform the powder.Various materials including metals, insulators and plastics may beformed into three dimensional shapes by these processing techniques.

A different type of processing occurs when a print head is used todeposit material onto the powder. The deposit may chemically react withthe powder or may be an adhesive that consolidates the powder into anadhered location. The prevalence of high resolution printing technologymay make this type of additive manufacturing process cost effective.

The field is both established, with versions of additive manufacturingbeing practiced for decades, and emerging, with new techniques andmaterials being defined with rapidity. The technology may be currentlylimited by the dimensions of objects that may be produced. Accordingly,it may be desirable to develop methods and apparatus that may allowadditive manufacturing techniques and apparatus to be independentlymobile.

SUMMARY OF THE INVENTION

Accordingly, the present disclosure provides description for methods andapparatus that allow for mobile additive manufacturing. In someexamples, the mobile additive manufacturing apparatus may act in anindependent or automated manner. The apparatus that performs the mobileadditive manufacturing may be called an Addibot (ADDItive roBOT).

An important characteristic of additive manufacturing apparatus may bethat material is added to a product in a controlled manner that isdriven by a digital model that resides in a controller. Through theprocessing of the additive manufacturing apparatus the digitalrepresentation may be translated to a physical approximation of materialplaced in three dimensional space.

Accordingly, in some examples disclosed in this disclosure, a mobileadditive manufacturing apparatus, which may be called an Addibot, may beconfigured to comprise a drive system which may be operative to move theapparatus along a surface. In some examples the Addibot may functionwith no physical tether. In addition, the Addibot may comprise anavigation system which among other functions may determine theAddibot's current location and its current bearing or direction that itwould travel in when caused to move or is travelling in if moving.

The Addibot may additionally comprise a controller capable of executingcode which may perform an algorithmic function. In some examples such acontroller may also be classified as an algorithmic processor. Thecontroller may also provide controlling signals to other elements of theAddibot. The Addibot may additionally comprise an additive manufacturingsystem to deposit a material or combination of materials in prescribedlocations across the surface that the Addibot is on or will move toduring its processing. The additive manufacturing system may addmaterial to a surface based on a digital model that may be processed inone or more controllers that may be located in the Addibot. The originof the digital model may be determined externally to the Addibot oralternatively may be determined by sensing or other processing of theAddibot, or may be a combination of external model definition combinedwith the data related to sensing apparatus within the Addibot. Thesystems that the Addibot has may be powered by a power system capable ofproviding power to operate at least the drive system, the navigationsystem, the control system and the additive manufacturing system of theAddibot. In some examples multiple power systems may be present in anAddibot.

The additive manufacturing system of an Addibot may include manydifferent types and definitions capable of adding material based on adigital model in controlled fashion. In some examples, the additivemanufacturing system may comprise a three dimensional (“3D”) printinghead. The printing head may add material to a surface in many standardmanners including extrusion of a material by the printing head orejection of material in liquid or solvated form. In some examples, the3d printing or three dimensional printing head may comprise an array ofnozzles which individually eject liquid form droplets in response to anelectronic control signal provided to the nozzle. In some examples, theliquid that may be processed by the 3d printing head may comprise one ormore of water, a water or aqueous solution, a hydrocarbon based solvent,an inorganic solvent or an emulsion of a combination of two or more ofwater, hydrocarbon or inorganic based solvents. Solutions may comprise amaterial solvated in one or more of the water, hydrocarbon or inorganicbased solvents.

In another aspect, a dimension of time may be included wherein one orboth of: a) a specified rate of extrusion and b) a specified order ofextrusion is controlled in order to obtain a desired result. Embodimentsmay accordingly include a ratio of time over distance and rate ofextrusion.

In some examples, the Addibot may also comprise a vision system. Thevision system may be operant to create a digital model of the topographyof a surface in a region proximate to the mobile additive manufacturingapparatus. The vision system may operate on or within the Addibot anduse a variety of detection schemes for analyzing the surface andcreating the model of the surface including light or laser based imagingtechniques or other electromagnetic radiation based imaging includinginfrared, ultraviolet or other electromagnetic radiation sources. Insome examples, the vision system may utilize sound based radiations tocreate a digital model of its surroundings which may include the surfacein the region of the Addibot. In other examples, the Addibot may deploya physical sensor to determine the topography of the surface in a regionstudied by the vision system. A controller located within the Addibotmay initiate the operation of the vision system and may receive signalsin response to the metrology that the vision system performs. In otherexamples, the Addibot may communicate with a vision system that islocated external to itself or on another Addibot for example.

In some examples, the Addibot may also comprise a material storagesystem capable of storing at least a first material to be supplied tothe additive manufacturing system. The stored material may includesolids, powders, gels, liquids or gasses, to mention some non-limitingexamples. In some examples, the material may be in wire forms or in someexample may exist as physical solid entities which are placed by theadditive manufacturing system. The material storage system may maintaina storage condition for the material by controlling an environmentalcondition. The condition that may be controlled may include one or moreof temperature or pressure of the material.

In some examples, the Addibot may also comprise a surface preparationsystem. The surface preparation system may be capable of removing one ormore of flaked surface material, dust, dirt and debris from the surfaceregion in a region in advance of the additive manufacturing apparatus.Since the Addibot may move or when stationary the additive manufacturingsystem within the Addibot may move in a direction, the surfacepreparation system may be operant to process a region of the surfacewhere the additive manufacturing system on its own or under the drivesystem of the Addibot may move to.

In some examples, the Addibot may also comprise a communication systemthat may be capable of transmitting signals outside the mobile additivemanufacturing apparatus. In some examples users may use communicationssystems external to the Addibot in transmitting a control signal orcontrol signals to the Addibot. The communication system may also becapable of receiving signals originating outside of the mobile additivemanufacturing apparatus. In some examples, the signals transmitted orreceived may comprise one or more of radiofrequency signals, infraredsignals, optical signals or sound based signals or emissions asnon-limiting examples. In some examples the communication system mayfunction to sense the environment of the mobile additive manufacturingapparatus. The sensing may occur in addition to signal transmissionfunction. In some examples, there may be multiple communication and/orsensing systems within an Addibot.

In some examples, the power system of an Addibot may comprise a battery.

In some examples, the power system of an Addibot may comprise acombustion engine or other type of engine.

In some examples the power system of an Addibot may comprise anelectrical wire that may be connected to an electrical power source thatmay reside external to the Addibot which may also be called a mobileadditive manufacturing apparatus.

There may be numerous methods related to a mobile additive manufacturingapparatus. In some examples a user may transmit a signal to an Addibotwhich may include any of the types of examples of apparatus that havebeen described. The transmitted signal may cause the Addibot to nextdeposit a first layer of material on a surface utilizing systems of theAddibot. The Addibot may, in continued response to the initial signal,move from a first location to a second or different location. Aftermoving the Addibot may in further continued response to the initialsignal deposit a second layer of material. The makeup of the first layerand second layer of material may be different in composition or physicalaspects such as thickness or may be identical except in the aspect thatit is located in a second location.

In some examples, the methods may additionally include a step to orientthe apparatus for mobile additive manufacturing, which may be called anAddibot, in a spatial coordinate system.

In some examples, the methods may additionally include a step to performa metrology process to measure the topography of a region of a surface.This may typically be in a region proximate to the Addibot or in aregion that the Addibot will move to. In some examples additional stepsin the method may include processing the result of the metrology processand using the result of the processing to control the additivemanufacturing system of the Addibot.

In some examples the methods relating to processing by an Addibot mayinclude the step of depositing a layer where a material comprises water.In some of these examples, the surface upon which the material isdeposited may be comprised of water. In some of these examples, thesurface comprised of water may be a surface where the water is in asolid form, which may be water ice.

A system of one or more computers may be configured to performparticular operations or actions by virtue of having software, firmware,hardware, or a combination of them installed on the system that inoperation causes or cause the system to perform the actions. One or morecomputer programs may be configured to perform particular operations oractions by virtue of including instructions that, when executed by dataprocessing apparatus, cause the apparatus to perform the actions. Onegeneral aspect includes a mobile additive manufacturing apparatusincluding: a drive system operative to move the apparatus along asurface; a navigation system to determine location and bearing; acontroller capable of executing algorithms and providing controlsignals; an additive manufacturing system to deposit a material orcombination of materials in prescribed locations across the surfaceaccording to a digital model processed by the controller; and a powersystem capable of providing power to operate at least the drive system,navigation system, control system and additive manufacturing system.Other embodiments of this aspect include corresponding computer systems,apparatus, and computer programs recorded on one or more computerstorage devices, each configured to perform the actions of the methods.

Implementations may include one or more of the following features. Theapparatus may include examples where: the additive manufacturing systemincludes a 3d printing head. The apparatus may include examples where:the 3d printing head includes an array of nozzles which individuallyeject liquid form droplets in response to an electronic control signalprovided to the nozzles. The apparatus may include examples where: theliquid includes one or more of water, an aqueous solution, a hydrocarbonbased solvent or an emulsion including water or hydrocarbon basedsolvent. The apparatus additionally including: a vision system to createa model of a topography of the surface in a region proximate to themobile additive manufacturing apparatus. The apparatus may includeexamples where: the controller provides control signals to the visionsystem to initiate its operation and receives electrical signals inresponse to a metrology processing. The apparatus additionallyincluding: a material storage system capable to store at least a firstmaterial to be supplied to the additive manufacturing system. Theapparatus may include examples where: the material storage systemmaintains storage conditions by controlling one or more of temperatureand pressure. The apparatus additionally including: a surfacepreparation system capable to remove one or more of flaked surfacematerial, dust, dirt and debris from a surface region in advance of theadditive manufacturing system. The apparatus additionally including: acommunication system capable of transmitting signals outside the mobileadditive manufacturing apparatus and receiving signals originating fromoutside the mobile additive manufacturing apparatus. The apparatus mayinclude examples where: the transmitted signals include one or more ofradiofrequency, infrared, optical or sound based emissions. Theapparatus may include examples where: the communication system mayfunction to receive information about an environment of the mobileadditive manufacturing apparatus. The apparatus may include exampleswhere the power system includes a battery. The apparatus may includeexamples where the power system includes a combustion engine. Theapparatus may include examples where the power system includes anelectrical wire connect to a power source external to the mobileadditive manufacturing apparatus. The method additionally including:orienting the apparatus in a spatial coordinate system. The methodadditionally including: performing a metrology process to measure atopography of a region of the surface. The method additionallyincluding: processing the result of the metrology process with analgorithm, and controlling the additive manufacturing system based on aresult of processing the result of the metrology process with analgorithm. Implementations of the described techniques may includehardware, a method or process, or computer software on acomputer-accessible medium.

One general aspect includes a method for treating a surface including:transmitting a control signal to an apparatus, where the apparatusincludes: a drive system operative to move the apparatus along asurface; a navigation system to determine location and bearing, acontroller capable of executing algorithms and providing controlsignals, an additive manufacturing system to deposit a material orcombination of materials in prescribed locations across the surfaceaccording to a digital model processed by the controller. The methodalso includes a power system capable of providing power to operate atleast the drive system, navigation system, control system and additivemanufacturing system. The method also includes depositing a first layerof a material on a surface utilizing the apparatus. The method alsoincludes moving the apparatus to a different location. The method alsoincludes depositing a second layer of the material on the differentlocation of the surface. Other embodiments of this aspect includecorresponding computer systems, apparatus, and computer programsrecorded on one or more computer storage devices, each configured toperform the actions of the methods.

Implementations may include one or more of the following features. Themethod additionally may include orienting the apparatus in a spatialcoordinate system. The method may additionally include performing ametrology process to measure a topography of a region of the surface.The method may additionally include: processing the result of themetrology process with an algorithm, and controlling the additivemanufacturing system based on a result of processing the result of themetrology process with an algorithm. Implementations of the describedtechniques may include hardware, a method or process, or computersoftware on a computer-accessible medium.

Implementation may include one or more of the following features. Themethod additionally may include providing a supporting surface, whereinthe supporting surface may be transparent to light in selected spectralregions. The method may additionally include orienting an Addibot to agiven location based upon a digital model and communication ofnavigation systems of an Addibot with navigation signals in theirenvironment. In some examples, an Addibot may detect locationinformation that is located upon the supporting surface that it ridesupon. The method may additionally include irradiating a material beneaththe surface by the action of a light producing component of the Addibot.In some examples, the light producing component may emit laserradiation. In other examples, the light produced may be focused intenselight from other sources. In some examples, a work product beneath thesupporting surface may be located beneath a layer of material. Thematerial may comprise liquid or powder forms of material that may changea chemical or physical characteristic upon irradiation with light ofselected spectral characteristics. In some examples, after receivingradiation upon the layer of material a next action may include loweringthe work product to create the ability to form another layer ofmaterial.

In some examples, a wall may be formed by the placement of moldingpatterns for a layer at a time. Thereafter, material may be filledwithin the deposit formed in the shape of the molding pattern to form asolidified form. A material which may be handled in a form consistentwith filling a deposit of molded material, where the material may thenbe solidified by its own internal reactions or by external forces orinteractions may be considered a solidifying material. Cement, asphalt,and polymer precursors may comprise some examples of solidifyingmaterials. In some examples the molded patterns may have internal closedshapes within them, and when a material is filled within the depositformed by the molding pattern it may not fill these internal closedshapes. In some other examples, numerous layers of molded material maybe formed by lifting the Addibot from layer to layer before material isfilled into the molded patterns.

In some examples, the molded patterns may have numerous internal regionsdefined. Some of the internal regions may be filled by materials tocreate a wall type structure. Other internal regions may be leftunfilled, or may be filled with other materials such as electrical wiresas a non-limiting example. In some examples, the molded patterns may beused to create novel and advanced roadways. A variety of patterns mayform single layer structures that may form features to strengthenroadways. In other examples cavities or channels may be formed into themolded material through which wires or other forms of electricallyconductive material may be placed.

The resulting structures may create an infrastructure for advancedroadways through which electrical signals may be communicated. Someexamples may include power and charging electrical devices, transmittersof various kinds in roadway, and transmitters of various kinds alongsideof roadway. Some transmitters may communicate via wired means and othersmay communicate at least in part by wireless means. Within a constructedroadway as described in this disclosure there may be devices to controlor generate signaling information for location, signaling informationrelating to the status of the roadway or sensors within the roadway. Insome examples, roadway systems may be configured to transmit data alongthe path of the roadway. In some examples the transmission along theroadway may comprise completely wireless communication in other examplesa combination of wireless and wired, sometimes with portions of the pathbeneath the roadbed may occur. There may also be communication fromsystems to equipment in the vicinity of the roadway and to neighboringcommercial and residential structures.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, that are incorporated in and constitute apart of this specification, illustrate several examples of the inventionand, together with the description, serve to explain the principles ofthe invention:

FIG. 1 illustrates a block diagram of the exemplary general componentsof a mobile automated additive manufacturing apparatus.

FIG. 2 illustrates a perspective view of an exemplary Addibot that maybe useful for Ice Surface Treatment.

FIG. 3 illustrates a perspective view of an alternative example of anAddibot with a drive system that may allow for the non-interaction ofthe drive components with a surface under processing.

FIG. 4 illustrates an exemplary depiction of an Addibot that isconnected to a front drive system as a trailer.

FIG. 5 illustrates an exemplary Addibot design for traversing andtreating surfaces with large height components.

FIG. 6 illustrates an exemplary Addibot in the middle of performing anadditive manufacturing build process on the surface of sheets ofmaterial which are added together to form a product.

FIG. 7 illustrates a processor and controller that may be useful invarious examples of Addibots.

FIG. 8 illustrates exemplary methods related to various examples ofAddibots.

FIG. 9 illustrates an example of an Addibot design for traversing andtreating surfaces that have a vertical component.

FIG. 10 illustrates an example of a suspended Addibot design fortraversing and treating surfaces that have a vertical component.

FIG. 11 illustrates an example of a supported Addibot design fortraversing and treating surfaces that have a vertical component.

FIG. 12A illustrates an exemplary system for operating an Addibot on atransparent support over a surface.

FIG. 12B illustrates a top view of an exemplary system for operating ateam of Addibots on a transparent support over a surface.

FIG. 12C illustrates a view of an exemplary extrusion component.

FIG. 12D illustrates a view of an alternative exemplary extrusioncomponent that may be useful in creating molded extruded features.

FIG. 12E illustrates a view of an alternative exemplary extrusioncomponent and structures that may be formed by repeated use of thecomponent.

FIG. 13A illustrates a perspective view of a portion of an Addibot thatcontains exemplary molding components in an exemplary shape for wallbuilding.

FIG. 13B illustrates a perspective view of the portion of an Addibotillustrated in FIG. 13A wherein the molding component is illustrated ina position after molding.

FIG. 13C illustrates a continued progression of an exemplary Addibotmolding component in use to create wall structures.

FIG. 14A illustrates exemplary advanced roadway structure that may beformed by Addibots.

FIG. 14B illustrates an exemplary Addibot in concert with features of anadvanced roadway.

FIG. 15 illustrates an exemplary roadway with features requiring repairprocessing.

FIG. 16A illustrates exemplary methods related to repair of exemplarypot hole type road defects.

FIG. 16B illustrates exemplary methods related to repair of exemplarycrack type road defects.

FIG. 17 illustrates an exemplary roadway in concert with an exemplarytransportation vehicle capable of interacting with the advanced roadwayin similar fashion to those capabilities employed by Addibots used inroadway construction and repair.

FIG. 18 illustrates exemplary methods related to various examples ofAddibots.

DETAILED DESCRIPTION OF PREFERRED EXAMPLES

The present disclosure relates to methods and apparatus for mobileautomated additive manufacturing. As used herein, “mobile automatedadditive manufacturing” may include control of locomotion of an additivemanufacturing apparatus over a surface free of tracks or rails.

Referring to FIG. 1, 100, some elements of an exemplary mobile additivemanufacturing system (110) may be found. The system may have a drivesystem 120 enabling transportation of the manufacturing system over asurface. The drive system 120 may function to move the apparatus on bothflat and shaped or curved topography. The drive system 120 may functionon wheels, balls, tracks or other means of conveyance known in the art.In some examples, the use of automotive or truck frames either withtrailers or with modification directly to the frame itself may be used.The drive system 120 may incorporate a drive mechanism comprising anengine or motor that may act upon the conveyance elements such as wheelsor may utilize transmissions and axles to drive the conveyance elements.Various forms of directional or steering control may be possible. Insome examples, the differential control of multiple motors acting uponconveyance elements may allow for directional control. In otherexamples, the directional control may function by a steering system thatmoves the conveyance elements in ways other than in its drive sense.

The mobile additive manufacturing system 110 may include a Navigation,Control and Sensing system 130 that may function to determine a currentlocation to a desired degree of accuracy as well as an orientation ofthe device at that location. Such information may be useful inregulating direction control through the navigation system and indetermining other control variables such as speed. The sensing systemmay provide other environmental information to the control system suchas temperature and humidity at the location and in some examples at asurface beneath the location of the system. In addition, the sensor andnavigation elements may also function to provide awareness of obstaclesin the environment of the mobile additive manufacturing apparatus. Aseparate vision, measurement and inspection system may be present insome examples (a following discussion discusses this in detail) and mayinterface with the control elements or sensing elements. The controlelements may receive data in various forms and may process the datautilizing computational hardware and programing algorithms. Theprocessing may produce control signals to engage the mobile additivemanufacturing apparatus to produce an environmental change such asadding material of various forms to create three dimensional surfacecharacteristics such as a flat surface, a surface of defined topographyor a surface where defects of various types are affected with theaddition of material. In other examples, the addition of material may beused to create an image or another functional aspect such as a slipresistive coating or a tread cleaning function as examples.

The navigation element may utilize various protocols to generatelocation awareness. For example, the element may utilize GPS technology.In other examples, a local transceiver network may provide telemetrylocal relative location awareness through the use of RF systems, orlight based systems such as a laser based system This local system mayfunction within an outdoor region or alternatively be set up to functionwithin a building. Cell phone based telemetry, and other schemes such asseismic location detection may provide information for telemetry. Insome examples, the navigation element may provide a first ordertelemetry to an accuracy required to control movement of the apparatus,for example. The vision system (to be discussed) or other sensingelements may provide a next higher accuracy for calibration of location.Location marks may be present upon or within the surface and a sensorsuch as a camera system, for example, may pick up the location marks tocalibrate the navigation system and the control system. Various otherreference elements such as physically defined lines, such as found onroads or parking lots may be a type of navigation control system. Stillfurther examples may involve the embedding of conductive wires to createa navigation information system. A grid of such conductive wires maycreate a calibrated work floor with a good deal of accuracy. In stillfurther examples, the surface to be acted on by the mobile additivemanufacturing apparatus may be a temporary surface that may itself bemoved. Sheets of a temporary material may function as the surface andthese sheets as well may include coloration and/or physical elementssuch as embedded conductors to provide a telemetry signal for thenavigation element.

The Navigation, Control and Sensing system 130 may function to define apath that the mobile additive manufacturing apparatus follows in itsprocess. In other examples, the path itself may be figured into thedesign of a desired topography. For example, in some examples it may benecessary for the mobile additive manufacturing apparatus (Addibot) totravel along a road surface and perform additive manufacturing based onaspects that it measures or determines of the surface as it travels. Inother examples, the shape of a feature to be deposited across a surfacemay involve the control of the navigation system to move the Addibot toa location where the additive manufacturing element can further controlthe additive process. In these cases, the path of the Addibot could bearbitrarily complex based on a model that it follows to generate an endresult.

Referring now again to FIG. 1, an additive manufacturing element 140 maybe represented. The various techniques known in the art may be includedas an additive manufacturing element including, for example, extrusionheads, stereolithography processing heads and material printing heads.An altered version of stereolithography may occur by the application ofthin films of liquid material upon the surface which is thensubsequently processed to create hardened surfaces. If the unreactedmaterial is removed a subsequent application of liquid reactant canbegin to build the next layer.

The material printing heads may have a wide diversity incharacteristics. Printing heads with very fine resolution may beutilized. In other examples larger volumes of material may be printedwith heads that have gross resolution. As an example, a printing headmay have rows of print heads that have an orifice size such that aroughly millimeter sized droplet may be formed. Such a droplet may havea volume of roughly 10-100,000 times that of a droplet from a 1:1000resolution. The volume of a millimeter diameter droplet may have anestimated volume of about 0.4 microliters.

In some examples, the additive process can relate to an element such asa print head depositing droplets of material over the surface to buildstructure. In stereolithography, an energy source is used to convert theliquid to a solidified material, but in these other examples, thedroplets of material may either react with the surface or solidify byother principals such as by cooling for example. Combinations ofdroplets of different material may also result in reactions that resultin solidified material. The additive manufacturing element may alsofunction to add material that changes color or pattern or other physicalproperties in select regions. A version of this type of additivemanufacturing may occur when powders are deposited in the additiveprocess. The powder may create lines or other demarcations. In some ofthese examples, a subsequent sealing of the powder form may be depositedby another additive manufacturing process.

In some examples, the additive manufacturing element may be an energysource such as a laser, ion beam or the like. The energy source may beused to cause liquid material to solidify in defined regions. The liquidmaterial may be added by the Addibot or be present by other means. As anexample, an Addibot may ride upon a transparent surface that may sitabove a liquid reservoir of relatively arbitrary size. An Addibot with alaser may ride upon the transparent surface and irradiate the surfacelayer of the reservoir in desired locations. After a layer is processed,the work material beneath the transparent surface may be moved away fromthe transparent surface by a layer thickness and the Addibot may againmove around on the transparent surface irradiating through the surfaceto image polymerizable material beneath.

The various additive manufacturing elements that may be used in thesemanners comprise the art that is consistent with mobile automatedadditive manufacturing.

An additive manufacturing element 140 may be part of the mobile additivemanufacturing system. There may be numerous types of additivemanufacturing elements consistent with this type of system. For example,in some examples, the material to be added may be found in a liquid formeither in its nascent form or in a processed form. The liquid materialmay be processed by droplet ejection printing schemes. Some printingelements may be comprised of MEMS jet printing elements. In otherexamples, the printing element may be composed of an array of valvesthat open and close to dispense controlled amounts of the liquid. Instill further examples, a liquid stream may be controlled by thepresence of mechanical shunts which do not allow a stream of the liquidto be released below the element. In fact, any liquid control mechanism,typically deployed in an array of elements, which may allow for aspatial control over the dispensing of the material, may comprise anadditive manufacturing element for liquids in a mobile additivemanufacturing system

In FIG. 1, a material storage system 150 may be found. As has beendescribed there may be numerous types and forms of material that may beprocessed by an Addibot. In some examples, materials in filament formmay be used; in other examples liquids of various kinds may be employed.And, in still further examples, solids such as powder form materials maybe utilized. In each of these cases, there may be numerous materialoptions within a particular kind. There may be standard ABS plasticfilaments or other plastic filaments. In some examples, other fiberssuch as fiber class filaments may be utilized in composite processingsuch as with epoxy resin combinations with fiberglass filaments. In theliquid form a great diversity of materials may be used including resins,photoactive and thermo active materials. Other materials in the liquidform may be a solid at an ambient condition but may be processed by theadditive manufacturing system at conditions that make the materialliquid. The powder form examples may be thermo-active and photoactivematerials or alternatively may be materials that in combination withother deposited materials cause a reaction to occur resulting in adeposited solid material. In the state of the art, metals, insulatorsand ceramics to name a few materials may be formed by the processing ofpowder form materials. In other examples, the powder deposited willremain in a powder form on the surface.

In the various materials examples that may be possible with an Addibot,the environmental storage conditions on the Addibot may be important.Accordingly the material storage system 150 may have controls overnumerous environmental conditions such as the temperature of thematerial storage, the pressure, the ambient gasses or a vacuum conditionand the humidity to mention some examples. Thus, the material storagesystem for an Addibot would have control systems for the importantenvironmental conditions. The storage system would need to allow for theautomated or non-automated replenishment or replacement of the materialthat is located in an Addibot. In some examples various combinations ofmultiple material storage systems may be present. For example, a powderstorage system and an additive manufacturing element for powder formsmay be combined with a liquid storage system and an additivemanufacturing element for liquid forms upon the same Addibot system. Instill further alternative, two different forms of material may becombined with different storage systems that feed a single additivemanufacturing element that is designed to simultaneously process the twomaterial types.

Other examples may have additive manufacturing elements to dispersesolids. The element may extrude elements of material that may be gelledto allow for the material to be formed by the additive manufacturinghead. The extrusion elements may also deposit small pieces of extrudedmaterial that is in a gelled or partially melted form. Lasers or otherhigh energy sources may cut the small pieces from the extrusion printhead as it is being extruded. In other examples, the material is not cutas it is formed into three dimensional shapes.

Solids may also be dispersed in powder forms. The powder may be carriedin a solvent as an emulsion that may be dispersed in manners thatliquids may be dispersed. In other examples, the powders may becontrolled by valves or shunts as it is dropped or impelled onto thesurface.

The various materials that are added to the surface may be furthertreated to form a solidified surface. In some cases, materials may betreated with light or other energy to heat or otherwise react thematerials to form a solidified result. In other cases, a chemicalreaction may be caused to occur by the addition of a second material. Insuch cases the additive manufacturing element may be comprised ofcontrol elements to disperse liquids and solids or multiple liquids. Inaddition, the system may include the elements to post process thematerial such as by thermal or photochemical action. These postprocessing elements may be located on the additive manufacturing elementor may be located in other portions of the system. In some examples, thepost processing may also include processes to wash or clear the surfacefrom materials that are not solidified, adhered or attached to thesurface. These processes may include processing to remove solid, powderor liquid material remaining on the work surface such as vacuuming orsweeping. The removed material may be recycled into the material storagesystem or may be moved to a waste receptacle. In similar fashion thepost processing steps to remove material may be performed by elementsthat are included on the additive manufacturing element or additionallybe other elements that are included in the mobile additive manufacturingsystem.

The results of the various additive processes may be measured by variousmanners to verify the conformity of the result to a modeled surfacetopography. An inspection system or a vision system 160 may performthese measurements to control the results. In some examples, the surfacemay also be studied with a similar or identical metrology element todetermine the presence of topography. Another way of looking at such ameasurement before the additive manufacturing step may be to examine thesurface for defects, cracks or fissures that may need to be processed toform a flat surface for example. Therefore, the vision system 160 may infact occur multiple times in the system. A pre-measurement may beperformed by a first measurement element and a post processingmeasurement may be performed by a second measurement element. There maybe numerous manners to measure the surface topography. As an example, alight or laser based metrology system may scan the surface and analyzethe angle of reflected or scattered light to determine topography.Similar scanning systems based on other incident energy like sound orelectromagnetic signals outside the visible spectrum like infrared or UVradiation, for example, may be used.

A different type of metrology system may result from profilometry wherean array of sensing elements may be pulled across the surface and bedeflected by moving over changes in topography of the surface. An arrayof deflecting needles or stylus may be dragged over the surface. In analternative example, a pressure sensitive surface may be pulled over thesurface under study.

The surface that the mobile automated additive manufacturing system actson may have movable defects that exist on it. This may be commonlyclassified as dust or dirt for example. An element for preparation ofthe surface 170 may be located in an Addibot. In some cases, thematerial may be removed by a sweeping or vacuuming process that movesthe particles into a region that removes them from the surface. Othermethods of removal, which may replace or supplement the sweeping orvacuuming, may include pressurized gas processing which may “blow” thesurfaces clean. There may also be electrostatic processes which chargethe particles with electric charges and subsequently attract them tocharged plates which attract the particles away. A cleansing process mayalso comprise a solvent based cleaning process which may subsequently beremoved in manners mentioned earlier, in a combination of the Addibottechniques. A first Addibot may function to pretreat a surface in avariety of manners while a second Addibot performs a topography alteringadditive manufacturing process.

Another element, a communication system 180, of the mobile additivemanufacturing system may be found referring to FIG. 1. In general,Addibots may be used in combinations to perform functions. Toeffectively perform their function it may be important that the Addibotsmay be able to communicate with each other. The communication system mayalso be useful for communication between the Addibot and a fixedcommunication system. The fixed communication system may be useful forcommunicating various data to the Addibot as well as receiving datatransmissions from the Addibot. The data transferred to the Addibot mayinclude programming software or environmental target files or the datamay include environmental data such as mapping data or topological dataas examples. The communication may be carried by RF transmissionprotocols of various kinds including cellular protocols, Bluetoothprotocols and other RF communication protocols. The communication mayalso utilize other means of data transfer including transmissions ofother electromagnetic frequencies such as infrared and opticaltransmissions. Sound waves may be useful for both communication andspatial mapping of the environment of the Addibot. In some examples theAddibot may be tethered to at least a communication wire that may beuseful for data transmission.

Another form of communication may relate to visual based informationconveyed by the Addibot body itself. In some examples, the Addibot bodymay include a display screen to communicate information to thesurroundings in the form of graphic or visual data. As an example, thedisplay can warn people in the environment of the Addibot as to thefunction that the Addibot is performing and when and to where it maymove. Audio signaling may comprise part of the communication system inaddition. As well, the Addibot may be configured with a light systemthat can project visual signals such as laser patterns, for example.

The communication system may be useful to allow external operators toprovide direction to the Addibot. The directions may include the controlof navigation in both a real time and a projective sense. Users mayutilize the communication system to provide activation and deactivationsignals. Numerous other functional control aspects may be communicatedto control operation of the Addibot other than just the transfer ofsoftware programs including for example activation and control of thevarious subsystems.

A Power and Energy storage element 190 may be found within the mobileadditive manufacturing system. In some examples, an Addibot will betethered with a wire. The wire may be used for a number of purposesincluding providing power to the Addibot drive system or to an energystorage system within the Addibot. In many examples, the Addibot willoperate in a wireless configuration, and therefore, will contain its ownpower system in the mobile platform. Standard combustion engines andhydrocarbon fuels may comprise a power system along with a generatordriven by the engine to charge batteries as an electric charging system.In other examples, a battery powered system may power both the drivesystem with electric motors as well as the electronics and othersystems. The battery storage system may be recharged during periods ofnon-use and the components of such a recharging system may compriseportions of the power and energy storage element. In some examples wherethe Addibot operates in an automated fashion, the recharging of theenergy storage element may also occur in an autonomous fashion whetherit is recharging electrically or obtaining additional fuel stores.

There may be numerous manners to configure the novel mobile additivemanufacturing system that has been described. In the following examples,non-limiting examples are provided as examples of the different mannersthat the Addibot apparatus type may be utilized.

Ice Surface Treatment—Water Printing

One manner that an Addibot may be configured to perform is processingthat observes a local surface topography and adds material to make thesurface more flat. Cracks, fissures, divots and other local changes to asurface flatness may also be processed by adding an appropriate materialeither to fill in the cracks and fissure or otherwise reshape thesurface topography. Ice surfaces that are skated upon are a type ofsurface treatment need that such processing may be relevant to. Skatingcreates fissures and divots that overtime become a difficult surface toskate upon. The state of the art processing to create a resurfaced icesurface utilizes large driven machines that contain a cutting devicethat cuts the surface of the ice to a depth that generally removes theimperfections. A flooding layer of water is then applied to allow forthe surface to be rebuilt to a flat surface height. The added water bothrepairs the surface topography and also overtime replaces water that mayhave left the ice surface by sublimation.

Ice resurfacing provides an example for types of Addibots that addmaterial to surface to shape it or repair it. The generality of thistype of Addibot should not be limited by the specific aspects of such anapparatus when defined as an ice repair Addibot. Therefore, theinventive art is intended to embrace such alterations in defining novelmobile additive manufacturing apparatus.

An Addibot may provide an alternative method to repair an ice surface.By controlling the deposition of water by additive manufacturingprocesses the necessary amount of water to fill in defects in thesurface may be applied. An additive manufacturing element for water, insome examples, may comprise a MEMS controlled print head that istraversed above an ice surface at a close height. The droplet size mayassume various dimensions depending on the nature of the additivemanufacturing element. In some examples, the print head may ejectdroplets of controllable sizes that are roughly in a range around amillimeter in dimension. Other processes may utilize print heads thatform droplets that are a tenth or a few hundredths of a millimeter indimension or alternatively may range to 10 millimeters or more. An imageof the surface may be compared against a desired topography and adifference may be calculated which may drive the amount of materialdeposited at a location by the additive manufacturing element.

The temperature of the deposited water may be controlled to be near orat the freezing point of water. In some examples, the water may be supercooled such that it still exists as a liquid but may solidify uponinteraction with the surface. In some examples multiple additiveelements may be utilized to deposit water under different conditionssuch as for example at a higher temperature such that in a secondadditive process the droplets have additional time to flow before theysolidify. There may be numerous processing conditions that may becontrolled in the deposition of water onto an ice surface.

In some examples, such as ice surfaces for general recreational skatingand ice related sports such as ice hockey and figure skating, thesurface of the ice may be desirably formed into a planar flat surface.In other examples, such as may be used in treating the surface for speedskating, there may be a need to condition the ice surface to be locallyflat but to have different planar orientations along the course of theice surface or in some examples may even have more complex shapes thatplanar.

Referring to FIG. 2, 200 an example of an Addibot configured for IceResurfacing may be found. The chassis 210 of the Addibot may contain andsupport the systems of the Addibot in a mobile and autonomous manner.

The drive system 220, and drive flexible wheel 225 of this example maybe exhibited. The depiction provides an example of one possible drivesystem using three wheels. An example using 4 or a different number ofwheels may also be within the scope of the inventive art herein. Thedrive system may be constructed, though, in a manner in which it doesnot interact with the other Addibot systems, for example, the visionsystem or the additive manufacturing element system. Depending on howthe wheels of the drive system 220 are powered, they may also be part ofthe navigation, control and sensing system. Based on the input from thevision system (as a part of the navigation control and sensing system)the wheels may direct the Addibot to its desired path, in a fashion thatis either autonomous or predetermined, depending on the orientation andnumber of the wheels.

A sensing element 230 may be depicted. This element may be used toperform functions necessary in the navigation, control and sensingsystem for this example. The navigation functions could be performedthrough GPS, an element grid, or other manners as has been describedrelating Navigation, Control and Sensing system 130 of FIG. 1.

An additive manufacturing element 240, and a secondary additivemanufacturing element 245 for this example may be shown. The additivemanufacturing element 240, for this example, may be a material printinghead, as described in reference to the additive manufacturing element ofFIG. 1, which may dispense water droplets of a controlled size, as wellas a controlled temperature (which may be controlled by the materialstorage systems). This element may function to execute a preciseadditive process of the material, based on input from the vision system.Another element, in this example, the secondary additive manufacturingelement 245 may be a roller or other type of distribution apparatus thatspreads or smoothens to a degree material that was added to the surface.

Elements of a material storage system 250 of this example are shown.These components may comprise various elements that may be necessary formaterial storage within an Addibot. There may be numerous alternativedesigns and orientations of components that may be consistent with thefunction of an Addibot. For this example, it may be important to includea surface material collection element which may be in part be filledfrom material outputted by the surface preparation system. A temperaturecontrolled portion of the surface material processing element may beused to melt collected ice. Filtration or screening components may beused to filter out any undesired particles that may be collected induring the process of the Addibot. A primary material reservoir wherewater or water based mixtures may be contained, may be filled by anoperator of the Addibot apparatus. Recirculation of melted ice collectedduring the surface preparation may also be directed to the primaryreservoir. An environmentally controlled secondary material reservoirmay also be used to keep water or water mixtures at a different storagecondition than that used in the primary storage location, such as thetemperature, pressure or other characteristic of the material. Thefilter system used in the surface material processing element could beany combination of ionizing plates, sieves, or other common filtrationdevices. These devices may be necessary for removing particles that maycontaminate or otherwise interfere with the correct operation of theAddibot.

A vision system 260 for this example may be depicted as shown. Thiselement may use a variety of methods such as those described inreference to vision system 160 of FIG. 1. These may include a laserscanner, sensitive extruding pins or brushes, or such components as mayallow for inspection of the surface to be process or for determinationof the topography of the surface. Alternative orientations may bepossible including for example an orientation where a vision system maybe placed behind the additive manufacturing element to perform apost-inspection of the surface, after the material has been applied.Among other purposes, the inspection may be used to verify the resultsof the addition process and to see if more or less material may need tobe added.

A surface preparation system 270 for this example may be observed. Inthis example, it may be necessary to remove ice particles, snow, dust,debris or dirt from the ice surface before it may impede the accuracy ofthe vision system in processing the surface topography. The elementsshown in FIG. 2 may include a brushing system, a vacuum system, and ascraping system or a combination of these. These systems may be used toremove undesired particles from the surface. Other particle removalsystems, including ionizing plates, a sweeping broom, or other brushbased devices, other types of vacuums or suction devices; high pressuregas treatments to blow surface debris into a collection region, amongother systems may also be usable for this example of an Addibot.

A communication system element 280 for this example may be seen. Thiselement may be used to carry out communication processes, either betweenother Addibots or an external user. These tasks may be carried out inmanners consistent with methods described in reference to thecommunication system 180 of FIG. 1.

A power and energy storage system 290 may be depicted. This element maybe a battery to power the example's electrical systems and motors, or acombustion engine to power the drive system which may also charge abattery system as non-limiting examples. The power system may providemechanical energy to the drive system or may provide electrical energyto the drive system which may power engines that comprise portions ofthe drive system. Electrical energy from generators connected tocombustion engines or from battery sources may be used to powersubstantially all of the electronic systems utilized throughout anAddibot. Other energy storage sources such as compressed air may alsocomprise acceptable solutions for energizing the operations of anAddibot.

In the example of ice surface treatment, the Addibot will typicallyperform processing on surfaces that are predominantly flat. While someAddibot designs may include frame adjustments and specialized drivesystems to support movement over terrain such as the schemes used forextraterrestrial robotics, an ice resurfacing Addibot may have differentchallenges for the drive system since the wheels need to accurately gripthe ice surface without changing it. Specialized drive systems may beuseful for many different Addibot design types.

The path that an ice resurfacing Addibot takes in the process ofperforming its function may be another example of a specialized aspectof these examples of Addibots. An ice rink or speed skating track may bephysically located in a fixed location. Therefore, the relative paththat an Addibot may traverse may be predefined or taught to the Addibotand replayed at later times. The control of the paths may also beprogrammed based on the types of use that the ice surface is exposed to.For example, an ice hockey game may have high use in goal creases, faceoff circles and such. The same ice surface may have a different usepattern after figure skating events, and such patterns could be flexiblyprogrammed.

Furthermore, during sporting events an ice resurfacing Addibot may notonly function to resurface the ice but also utilize display componentson its body to provide visual information as it moves on an ice surfacesuch as pictorial displays and laser light shows as non-limitingexamples. In such examples, the path of the Addibot may also be alteredto complement the non-resurfacing aspects.

In the performance of ice resurfacing, especially during sportingevents, the rate at which the ice surface is processed may becomplemented by the concerted processing of multiple Addibots. It may belikely in some examples that a team of five to ten Addibots may processthe ice surface during an intermission. In these cases, the Addibots mayneed to accurately communicate and sense the presence of other Addibots.In some of these examples, the concerted action may also involveprocessing by an external processing device that communicates with andto the Addibots. Proximity sensors in the communication or other sensingcomponents may operate as well to establish the presence of obstaclessuch as other Addibots or humans or other such obstacles that may bepresent on an ice surface.

Communication to the control systems may be performed by wirelesscommunication protocols such as Wi-Fi, Bluetooth, cellular communicationprotocols such as gsm, CDMA for example, and operate on differentcommunication channels and frequencies as have been discussed.Additionally, Addibots of various types may also comprise connectionsfor wired communication and also display screens and input/outputdevices to allow operators to provide control signals, data transmissionand other interaction with the Addibot.

The various systems of Addibots may necessarily utilize materials orother commodities such as energy during the course of processing. Thematerial storage systems may interact with fixed units that may refillthem or they may be filled by operators in a manual fashion. In theexample of an ice resurfacing Addibot the material storage system may berefilled with water for example.

In examples that utilize batteries as a power source, the batteries maybe powered at a charging station. The interaction of the Addibot with acharging station may be performed in an autonomous fashion where theAddibot moves itself into a proper location to interface with thecharging station. Alternatively, an operator may interact with theAddibot and connect it with a charging system.

Referring to FIG. 3, 300 an alternative example of an Addibot with adifferent drive system type may be found. In some examples, the wheelsof an Addibot may be configured to be parallel to each other on twosides of the Addibot. This means that there may be a rear drive system310 and a forward drive system 320. The design allows for less chancefor features to be interacted with by the drive system as the Addibotmoves in forward or reverse directions.

Other Examples of Addibots or Methods of Use of Addibots AdditiveManufacturing of Powders—Sports Field Maintenance

The material that is additively processed by an Addibot may includepowdered forms. In some examples, the powdered form may perform afunction without further processing, such as may be the case for anexample Addibot that is utilized for depositing lines of material suchas chalk upon a sports playing field. In other examples, the powder maybe further processed to result in an added material to the processedsurface. A chemical in a liquid form may be applied by the same Addibotor an additional Addibot or in some examples by another apparatus. Thechemical may cause a reaction to occur resulting in a hardened orsolidified material being present upon the portion of the surface thathad added powder processed. The further processing of the powder mayinclude treatment with a source of energy, such as a sinteringapplication that may be applied by laser irradiation or other thermalprocessing apparatus. In other examples, exposure to an energy sourcesuch as a lamp source may cause the powder to undergo a photo inducedreaction to result in a solidified, hardened or attached material uponthe surface that the powder was deposited. Other powdered materials ormixtures of powder materials may be deposited by an Addibot in anadditive manufacturing process.

Road Surface Maintenance—Cracks and Paint Lines

A surface may be treated by an Addibot to add material to determinedregions for the purpose of creating a new surface topography. In someexamples, the regions where material is added may be defective regionsof the surface that may result from cracking of the material that makesup the surface or other processes that may result in surface defects.The defects may be observed by a vision system located upon an Addibotor on another apparatus that communicates with the Addibot. Theobservations may result in a mapping of surface regions that materialshould be added to. In some examples, such as where the surface map mayrepresent defects in a road surface; liquids, powders, agglomerates orother mixtures of solids and liquids may be deposited by the Addibotinto the regions highlighted by the mapping.

In examples where the location of added material is provided to theAddibot a calibration process may be performed at one or more locationsduring the course of the operation of the Addibot. In some examples, analignment feature such as a printed mark which may be a cross orverniers for example may be place upon the surface by the apparatusperforming the observation of the defectiveness. The vision system ofthe Addibot may then function to observe the alignment marks and usethem to orient and calibrate its location and movements relative to themap space. In some examples, such as that depicted in FIG. 4, 400 anAddibot may be pulled behind a drive system in a trailer fashion. Afirst Addibot 410 may be connected to Addibot 420 by a hitch system 430.

Large Piece Manufacturing—Boat Hull

As depicted in FIG. 5, 500 a mobile additive manufacturing apparatussuch as an Addibot may be useful in producing large pieces by theperformance of mobile additive manufacturing upon a surface in a sheetform. The surface sheets 560, 561 may subsequently be moved into anoriented location 550 to be stacked in an aligned manner. In someexamples, the sheets are treated in such a manner that they adhere tothe surface that they are moved to. In other examples, the stackedsheets may be treated in a manner that solidifies them together such asheating for example. In such a case, the heating may 5activate athermo-epoxy in the sheet to adhere to a deposited layer lyingunderneath. The sheet material that is not attached to the depositedmaterial may be removed in various manners such as cutting or solvatingthen. In some examples, channels may be formed in the various additivelydeposited layers such that adhesive material may be poured through thestacked layers and cause them to consolidate into a strong product suchas a boat hull for example. This example may more generally becharacterized as an Addibot that functions as a mobile additivemanufacturing apparatus by moving an additive manufacturing head thatcan control material in an x and y plane as well as being translatedinto a vertical direction. The apparatus may then control depositionthat may be represented by x, y coordinates of added material of athickness z . . . and then the apparatus may subsequently be translatedto a new x′, y, and z′ location for further additive processing.Referring to FIG. 5, defined layer features 570 and 571 may have beenprinted in the manner shown for Addibot 510 printing features 520 on asheet 530 before the sheet is moved 540 onto the stacking fixture withoriented location 550. In this manner large products can be formed inthin layers by Addibots and then the sheets can be stacked. In someexamples, Addibots may perform the function of moving the sheets withdeposited layer features as well.

Surface Topography Forming—Skate Park

In some examples a composite surface may be formed by the additivedeposition of layers to form a support structure for other surfacetreatments. Layers of solidified material may be deposited by an Addibotapparatus. A subsequent process may coat these layers with a top surfacetreatment. In an example, a skateboarding park may be formed by theadditive deposition of surface material in topographic layers ofdeposited concrete for example. After curing, a subsequent process suchas manual forming may coat the rough surface layer with additionalmaterial to create a smoother surface. A large Addibot such as that seenin FIG. 6, 600 may be useful to allow for a large additive manufacturingsurface to be treated, as well as allowing significant height that theadditive manufacturing element may be located at as layers are added.There may be various components for the large surface additivemanufacturing system. The chassis 610 of the Addibot may contain andsupport the systems of the Addibot in a mobile and autonomous manner.The drive system 620 of this example may be exhibited. A sensing element630 may be depicted. An additive manufacturing element 640 for thisexample may be shown. Elements of a material storage system 650 of thisexample are shown. Elements of a secondary material storage system 655of this example are also shown. A vision system 660 for this example maybe depicted as shown. A surface preparation system 670 for this examplemay be observed. A communication system element 680 for this example maybe seen. A power and energy storage system 690 may also be depicted.

Surface Patterning—Entry Way Flooring

In some examples, an Addibot may add ink or other colorants to a surfaceunder treatment. The Addibot may move a printing head across a surfaceafter being oriented in space in some fashion. In some examples, theorientation may occur by the reading of a surface reference feature suchas a cross or verniers. In other examples, a wireless triangulationprotocol may be used which in turn functions through the use of radiowaves, light waves, infrared or ultraviolet waves, sound waves or otheremissions that could be used to triangulate a location. In someexamples, GPS protocols or cellular based location protocols may beuseful for orientation.

The oriented Addibot may print a colorant pattern across a large surfaceas it moves in a programmed manner. Such an Addibot may have multiplematerial storage locations to store different inks with different colorsto feed the additive manufacturing element which may in some examples bea MEMS based ink printing head. In some examples, after the printing orother additive manufacturing step that results in coloration, a postprocessing drying or curing step may be caused to occur by the action ofthe Addibot or a subsequent apparatus.

After a colored pattern is applied to a surface, it may be desirable toencapsulate the surface treatment with clear treatments of othermaterials such as clear coat paint, clear latex, urethane or othertransparent surfaces. An Addibot may be useful for the programmedadditive process of these clear coatings, or another apparatus or personmay treat the surface to coat the additively processed surface pattern.

In other versions of these examples, the urethane coating may be appliedin a step nearly identical to the printing step. In still furtherexamples, the MEMS printing element may apply very small droplets ofcolored urethanes or other transparent materials with dyes in them thatthen both form a surface pattern and also are a resulting surfacetreatment that is strong enough to be used without further treatment.The more general aspect of a mobile additive manufacturing apparatus mayallow for surfaces to be treated in a manner to form a pattern such thatthe surface may subsequently be moved. For example, wall treatments orsigns may be processed at a work site and added to a building as asurface in a different orientation from the orientation as processed. Asan example, patterned window coverings or signs may be formed with aprocess involving such a type of Addibot apparatus.

Organic Surface Treatment—Wood or Stone

In some examples, a surface such as a driveway may be treated with anAddibot that may be configured for programmed deposition on a surface.The Addibot functionality may be particularly useful in patterning thedeposition of surface treatments in such a manner that they are notapplied where the underlying surface is not, such as for example off thesurface of a driveway. In a similar fashion, organic material such ascoatings may be applied to other types of surfaces such as decks forexample. In some examples, the Addibot may use its vision system tounderstand where the planks are located and not the seams between themfor example. The Addibot may then control its additive manufacturingelement to add the organic coatings only in the region that a treatmentwill fall upon.

Surface Bonding—Rubber Walkway on Concrete

In some examples, an Addibot may add material to intentionally change asurface both in material composition and also in topography. An Addibotmay function to print or otherwise deposit liquid compositions that maypolymerize in place or otherwise solidify to create a structure that hasfunction. In a non-limiting example, a series of stripes may bedeposited on a concrete walkway near an entrance such that the stripeseither perform an anti-slip function or a drying function as a personwalks above the deposited material. The Addibot device may be used insuch a manner when the walkway is first formed or alternatively it mayperform a repair function to add more material as it is worn away. Thevision system of some Addibots may be particular useful if it measuresthe topography of the warn added stripes and determines the correctamount of material to additively process onto the surface such thatraised stripes of uniform height result.

Adding Solid Material in Mesh Matrix Form Followed by Sealing

In some alternatives an Addibot may add material in solid form to asurface and then subsequently treat the solid added material in spacesbetween individual pieces. As a non-limiting example an Addibot mayplace tiles on a surface in prescribed locations. In some examples anadhesive may be deposited onto the surface in appropriate locations forthe tiles to be placed into. In other cases, an additive process maydeposit adhesives or sealants between tiles after they are placed. Theadditive manufacturing element in these examples may not depositdroplets or liquids but solid elements at prescribed locations which maythen be locked in place as mentioned. Surface topography of suchcomposite surface may then have various properties that may be definedby the solid structures. In some examples, the solids may be ceramics orother insulators, in other examples; they may be metallic in nature. Instill further examples wire forms of material may be added to a surfacein similar fashion to the extrusion printing of gelled material to formadditively produced products. In some examples a metallic wire may bemoved by a head and may be affixed in a particular location by asimultaneous additive step for an adhesive as an example. In such amanner a surface may be built from solid materials such as wires whichmay later be embedded in another surface layer to result in sensors,heating elements or radio frequency transmission elements for example.In a more general sense, the mobile drive system may move an Addibotaround a surface while its additive manufacturing element adds solidform material to the surface.

Control Systems

Referring now to FIG. 7, a controller 700 is illustrated that may beused in some examples of a mobile additive manufacturing apparatus. Thecontroller 700 includes a processor 710, which may include one or moreprocessor components. The processor may be coupled to a communicationdevice 720.

The processor 710 may also be in communication with a storage device730. The storage device 730 may comprise a number of appropriateinformation storage device types, including combinations of magneticstorage devices including hard disk drives, optical storage devices,and/or semiconductor memory devices such as Flash memory devices, RandomAccess Memory (RAM) devices and Read Only Memory (ROM) devices.

At 730, the storage device 730 may store a program 740 which may beuseful for controlling the processor 710. The processor 710 performsinstructions of the program 740 which may affect numerous algorithmicprocesses and thereby operates in accordance with mobile additivemanufacturing equipment. The storage device 730 can also store Addibotrelated data in one or more databases 750, 760. The databases 750,760may include specific control logic for controlling the deposition ofmaterial at each of the additive manufacturing components which may beorganized in matrices, arrays or other collections to form a portion ofan additive manufacturing system.

While the disclosure has been described in conjunction with specificexamples, it is evident that many alternatives, modifications andvariations will be apparent to those skilled in the art in light of theforegoing description. Accordingly, this description is intended toembrace all such alternatives, modifications and variations as fallwithin its spirit and scope.

Methods

There may be numerous methods of utilizing an Addibot, manufacturing anAddibot or creating a product with an Addibot. Referring to FIG. 8, anexemplary set of method steps that may be commonly utilized in numerousexamples of Addibots are displayed. The steps are displayed in a flowchart for example. The steps may flexibly be used or not used and theorder of the steps may be changed within the scope of the inventive artof Addibots.

At step 810, an Addibot of a particular type may be obtained by a user.Next, at step 820 the user may transmit a control signal to the Addibot.The transmitting may involve numerous means including a wirelesstransmission, a wired transmission or a transmission involving aphysical interaction such as pushing a switch or a display panel of anAddibot. The initiation signal may cause a variety of responses that areproximately caused by the initiation even if further interaction withthe user is or is not required or if the Addibot will flexibly respondto its environment or programming thereafter.

At 830, in some examples the Addibot may perform an orientation step.This step may assess one or more of determining a spatial location in aspatial coordinate system and may also assess movement and direction ofmovement or potential movement in a spatial coordinate system.

At 840, in some examples the Addibot may perform a metrology process ona region of a surface. In other examples at 840 an apparatus external toan Addibot may perform a metrology process on a region of a surface andmay communicate information to an Addibot related to the metrology orrelated to the processing of the metrology data 850 in some form.

Additionally, at 850, in some examples the Addibot may process theresult of the metrology by means of a processor. In some examples, thesaid process may be one as described in FIG. 7.

At 860, in some examples the Addibot will utilize the information thatit has received in various manners about the surface and any desiredmodel that results from this information and based on a digital modelprovide controlling signals to the additive manufacturing system.

At 870, in some examples, the Addibot will deposit a first layer ofmaterial on a surface.

At 835, there may be a loop process that occurs in some examples andunder some situations that may cause the Addibot to return to step 830and continue processing. Alternative, in some examples, as shown at step845 a loop process may occur that may cause the Addibot to return tostep 840 and continue processing.

At 880, a step may occur where the Addibot is moved from a firstlocation to a second location. In some examples, a characteristics ofthis movement is that as part of the Addibot moving the additivemanufacturing system as a whole moves from a first location to a secondlocation even if portions of the additive manufacturing system couldmove some or all of the printing head or other additive element to thesame second location without a movement of the Addibot.

At step 890, the Addibot may deposit at the second location a secondlayer of material. The nature of the second deposit may comprise adifferent material, or a same material. The nature of the second depositmay comprise a different physical characteristic such as thickness orthe same characteristic as a first deposit. The second deposit may becontiguous with a first deposit but be located at a second location andbe considered a second deposit, by the very nature of being at a secondlocation.

Operation of an Addibot on Vertical Surfaces

Referring to FIG. 9, an exemplary Addibot design that may function on avertical surface is illustrated. In some examples, a purely verticalsurface may be processed by the Addibot; however, it may be possiblethat a “vertical” surface may be a wall or other surface that has atleast a component in a vertical dimension. There may be examples betweenvertical and horizontal that may be treated as a horizontal surfacemight be treated, as a vertical surface would be treated or as bothsurface types might be treated.

In FIG. 9, 900 may depict a vertical treatment. A wall 920 may have asignificant component in a vertical direction. Thus, an Addibot may needto be supported in a manner that overcomes a gravitational force thatmay not be completely supported upon wheels of such a device. Verticalmotion may be supported in some examples by rotary fans 930 which maydirect air to support the Addibot in a configuration or move it in otherconfigurations. There may be many types of rotary fan apparatus, such asthose deployed in helicopters, drones or the like. Combinations oflighter than air balloons with rotary fans may represent anotherexample.

An Addibot 910 which is deployed into a vertical direction may haveother alterations that are required to its components. As a non-limitingexample, the deployment of fluids by the Addibot may be affected by theorientation of the device relative to gravity. In some examples, pumpsmay be utilized to supplement previous effects that were related to theeffect of gravity. In other examples, valves may be used to counteractthe effect of orientation in a vertical direction upon materials withinthe device.

Referring to FIG. 10, an alternative vertical treatment 1000 may bedepicted. As an alternative example, the weight of an Addibot 1010, maybe offset by supporting members 1030. The supporting members 1030 maycomprise wires, rods or the like and may connect to a vertical supportmember 1020 that may be attached to the vertical surface or support forthe vertical surface.

Referring to FIG. 11, an alternative vertical treatment 1100 may bedepicted. In these examples, the weight of an Addibot 1110 may besupported by a supporting mechanism 1120. The supporting mechanism 1120may have components that allow for the raising and lowering of a supportfor the Addibot 1110 in a vertical direction. In non-limiting examples,the components that allow for raising and lowering may include “scissor”type support members as depicted in 1100 that raise and lower by theapplication of motors upon lead screws. In other examples, pistons andtelescoping members may be used in a manner to raise and lower thedevice in a non-limiting sense.

Operation of an Addibot Over Surfaces

In some examples an Addibot may be operated upon a surface where it actsupon material that is beneath the surface. Referring to FIG. 12A, anAddibot 1210 may be represented of various types described herein. Itmay operate upon surface 1220. Surface 1220 may be transparent to lightin various spectral regions. Directed light energy 1240 may be emittedby a component portion 1250 of Addibot 1210. The directed light energymay impinge upon a material surface 1260 of liquid or powder formmaterials. The light energy may induce a chemical or physical reactionupon the surface and cause it to solidify in predesigned conditions.Such an additive process may be consistent with description herein ofstereolithography processing. There may be other types ofstereolithography processing that may be processed with an Addibot upona surface.

In FIG. 12A the surface 1220 may be supported by support members 1270.The liquid or powder form materials may be located in a container 1275.In the case of liquid form material, the work object 1230 may besupported upon a stage 1235 that is translated down into the liquid aseach layer is processed. In powder form, the stage 1235 may likewise betransported in a vertical direction, then additional powder may be addedand shaped into a thin layer upon the work object.

There may be numerous Addibots that are acting upon the surface, and theobject to be fabricated may therefore be quite large. Referring to FIG.12B, multiple Addibots may be represented by Addibot 1210, secondAddibot 1211, third Addibot 1213, fourth Addibot 1214 and fifth Addibot1215. These Addibots may be supported by surface 1220 but act uponmaterial beneath the surface 1220 as described previously. There may benumerous means to communicate directions to the multiple Addibots tocoordinate their combined action upon the material beneath the surface1220. As well, upon the surface there may be features that locally andglobally provide alignment information for Addibots moving upon thesurface. Inset 1280 shows a blowup of a region of a surface with anexemplary grid 1285 depicted. The grid may be formed by variousmaterials. In some examples the grid may be created from material thatare transparent to the light energy 1240 but opaque at other wavelengthswhich may be used as means for an alignment system upon the Addibot todetect location. The grid may also include identification information invarious forms, such as bar codes, letters or other types of codes toidentify the location of the alignment feature. As well, the gridpattern may provide a location calibration signal, whereas other systemssuch as laser alignment or RF alignment systems may provide more globalinformation to Addibots on their location. In some examples, thealignment grid may comprise electrically conductive materials, andAddibots may physically or wirelessly connect to the grid pattern foralignment information.

Material Extrusion

Referring to FIG. 12C, an exemplary material extrusion device may befound. A heated extrusion head 1241 may heat extrusion material 1242.Some examples of extrusion material may include ABS, PLA and otherplastic materials that have relatively low melting temperatures. Afeeding apparatus 1243 may be used to feed extrusion material 1242 intothe heated extrusion head 1241. Molten or semi-molten material may beextruded through an extrusion head 1244 resulting in narrow meltedmaterial 1246 that may be formed upon a surface.

The extrusion of material may be performed in novel manners where thematerial may be extruded from a mold type shape where two faces are usedto contain the molten material in defined shapes. There may be numeroustypes of shapes that may be formed. Referring to FIG. 12D, a basicexample of an extrusion apparatus based upon parallel plates isdemonstrated. In some examples, the plates may be coated with materialsthat prevent the adherence of the extrusion material upon the surface.Examples of the coating may include non-stick Teflon based materials aswell as non-stick ceramic materials as non-limiting examples. In someexamples a wire form of the extrusion material 1253 may be fed into themolding apparatus by a feeder 1252. The region of the feeder 1252 may betemperature controlled, and at an elevated temperature to melt orpartially melt the extrusion material 1253. A rectangular extrusionregion 1254 may be formed by plates 1255 of coated material in someexamples. The plates 1255 may be heated by a heating device 1251. Theheating device 1251 may be a resistive heater, coil heater or otherdevice capable of heating the region during the extrusion of theextrusion material 1253. The region at 1251 may be kept at a differenttemperature than 1252 to allow for molten material to be forced onto asurface through the rectangular extrusion region 1254. The resultingextruded material may form a surface bonding region 1257 which may belarger than the rectangular extrusion region 1254 that the material wasextruded from. As one moves away from the surface the extruded material1256 may assume a shape defined by the rectangular extrusion region1254.

There may be numerous manners to extrude material in the deviceillustrated in FIG. 12D. In some examples, the feeding of extrusionmaterial 1253 may force the extrusion. In other examples pistons mayforce molten material into the extrusion device. In still furtherexamples, pressurized fluids or gasses may be used to force moltenmaterial out of a region where it is melted and into a molding form. Insome examples, complicated molding forms may be formed from coatedplates such as in the illustrative device in FIG. 12D. In some examples,versions of the molding form may be completed where the plates have theability to be moved relative to each other. In some examples, a wireform material will be introduced into a melting region, after asufficient time in the melting region, a control signal may causepressurized gas to push the molten material into the form. The form ormolding form may contain the molten material to a shape, and thereafter,as the molding form may be maintained at a lower temperature thematerial may slowly solidify in the shape of the molding form. In someexamples, one or more of the molding plates may be moved away fromanother releasing the solidified material in place. The mold or form maythen be moved upwards from the surface and in the process of movingrelease the formed molded material.

Referring to FIG. 12E, the exemplary formation of structures by therepeated processing of extrusion of molten material in molding forms maybe depicted. The details of the molding form may involve morecomplicated features 1261 than have been depicted such as end platesthat may be moved to allow for overlap with previously formedstructures. In FIG. 12E the result of three extrusion processes may bedepicted with seals between the process steps such as process step 1262and process step 1263. At process step 1262 vertical sides may beoverlapped and joined in various manners. In a non-limiting example,each of the sides may have overlapping features that repeat withadditional processing. For example, an end overlapping feature 1266, atop overlapping feature defined by edge 1265 and recessed edge 1264. Thefeatures and shapes are illustrated as non-limiting examples of how theextrusion devices may form various structures.

Exemplary Extrusion Components for Structure Formation in MobileAutomated Additive Manufacturing

Extrusion devices may be formed in various shapes consistent with theprocessing needs has have been described. Referring to FIG. 13A, aportion of an Addibot may be observed where a molding form portion ofthe Addibot may be depicted in isolation. In the example, a portion ofthe supporting chassis 1310 may be attached to the portions of theAddibot used to control movements of the device. The chassis may haveconnections to a molding device. The top of the molding device has beenexcluded in FIG. 13A to allow for an illustration of a relativelycomplicated mold form as shown. Features such as straight runs 1311 andinternal cylinders 1312, internal straight runs 1313 and internalchannels 1314 may be observed in the mold form. While the particulardesign of the mold form is shown as an example, it may be apparent thatmany alterations in design may be easily achieved; and in fact, versionsof the molding apparatus may be defined which may have their featureshape changed. Referring again to the exemplary mold form design in FIG.13A it may be apparent that the shape of an extruded piece defined bythe form may create an exemplary shape that may be filled with othermaterials such as concrete, plaster, mud and other materials consistentwith wall design. In some examples, features may be defined which mimicthe role and shape of studs in walls, where the walls may not becompletely filled. The channel and cylinder type features may be usefulfor creating gaps and channels in solidified walls that may in anexample be used to route wires, conduits, ducts and the like.

Referring to FIG. 13B, the exemplary Addibot with molding feature 1320for additive manufacturing may be shown in a position after an initialstructure has been formed by extrusion. The molding feature 1320 may belifted by various mechanisms within the body of the Addibot. Asmentioned previously, the molding features 1320 may have plates that maybe movable relative to each other. In some examples, after moltenmaterial is extruded into the mold and cooled to solidify the material,the molding feature 1320 may be lifted so that it resides fully abovethe solidified structure 1321 that may be formed according to thevarious types of methods described. The lifting mechanism may besupported upon the supporting chassis 1310 of the Addibot.

Referring to FIG. 13C, the exemplary Addibot may move to a nextprocessing position 1330. By moving, the previously formed solidifiedstructure 1321 is now exposed. The movement of the Addibot from onelocation to a next location may be controlled by a digital model thatmay reside in a controller in the Addibot. One aspect of an Addibot maybe that a digital model may be made to define a large structure thatwill be manufactured by an Addibot or a team of Addibots. In the exampleof FIG. 13C the structure being created may represent a wall beingbuilt. The wall may be built of extruded material. In some examples asingle level of extruded structures may be filled with a material toform a fortified wall. In some examples, the structures may be filledwith concrete, macadam, plaster, polymer, fluids or other materials. Aversion of an Addibot may be used to extrude these filling materialsinto the structures. In some examples, the extruded material structuresmay be formed in such a manner that an Addibot may ride at a secondlevel upon the first level structure that was formed. In some examples,a series of levels may be formed before the structure are filled withfortifying material. There may be various supporting equipment that mayaid in the processing of walls and other structures in this manner, suchas lifts, elevators, movable scaffolds and the like.

Advanced Roadway Construction with Addibots

Examples of structure building with extrusion components within anAddibot have been described in the recent section. Different versions ofextrusion components may be used to construct advanced roadways as well.The use of the term roadway in this disclosure is intended to embrace aninclusive definition as may be standard in the industry wherein aroadway includes the lanes for vehicular traffic, the shoulders alongthose lanes, medians between on-coming lanes, turning lanes, and marginsalong the shoulders to separate the roadway from its surroundings.Referring to FIG. 14A, some features that may be produced by an Addibotconfigured to support roadway construction may be observed. A roadway1410 may be formed in the various standard manners that such surfacesare constructed. There may be an interface 1420, where a roadwayaccording to the present disclosure has an advanced formed base with afilled bed material. Thereafter, Addibots may extrude various structuralfeatures. As an example, some roadway designs require the possibilityfor a roadway to expand under heat with expansion joints or otherexpansion elements. In some examples, an Addibot may extrude a featureat a location along the roadway surface. The location of the feature maybe present in a model of the roadway that exists in Addibots andcontrolling apparatus for an Addibot or combinations of Addibots. Theextruded feature may, as an example, be a channel that is formed at thefull height or nearly the full height of the roadway bed when theroadway is completed. In some examples, the channel may be filled with amaterial. In some examples the material filling the channel may be asealing material that may flexibly deform under thermal load and variouspressures and forces from both the roadway and eventual traffic alongthe roadway. In some examples, the material filled into the channel maybe a material such as a salt that will dissolve under the action ofwater to expose a well-controlled gap in the roadway.

Addibots may be used to extrude supporting meshes 1421 of various kinds,shapes and designs. In some examples an extrusion pattern may be across-hatch pattern. A cross-hatch pattern according to this disclosureis a pattern where two or more features of the pattern approximateintersecting lines. In other examples a unit cell pattern, where a unitcell pattern means a pattern where portions of the pattern are repeated,a beehive pattern or various other patterns that could be useful insupporting a roadbed under the various stresses that it is exposed to.In some examples, the extruded material may be a composite of moltenmaterial with embedded fibers, nanofibers, nanotubes and other materialswhich may increase strength, flexibility, ability to stretch and othermaterial characteristics that may be desirable for a supporting materialwhich may be embedded in a roadbed. In some examples, the bed of theroadway may be comprised of asphalt of a given thickness. As an example,consider a bed of 16 inch thickness asphalt. In some examples, theextruded supporting material may be a full six inch thickness, a portionof the six inches, or in some examples, the roadway may be formed inmultiple levels each one having another extruded layer. In someexamples, the extruded material may be formulated with supportingmaterial embedded within where the molten material may be chosen tofully or partially mix into the hot asphalt as it is laid. A partialmelt of the material may leave a strengthening pattern of fibers,nanotubes and the like within the roadway yet not create significantgaps within the roadway bed.

Another feature that may be added to the roadway surface may be achannel 1422 that may be used to embed materials such as conductivematerial within a roadway. There may be numerous uses for embeddedconductive material including sensing of various kind, communicationinterface through wireless means and communication routing along theroadway. As shown the channel 1422 may route electrical connectionsalong a roadway and may also route them to the side of the roadway atside channel 1423. The extrusion techniques and apparatus may be used toform channels as portions of the deposited material. The channel maycontain electrically conductive material with other materials as well.In some examples, the channel may contain communication devices such asoptical fiber. The optical fiber may route signals along the roadway aswell as to devices along or embedded within the roadway. The channel maybe filed with insulating materials of various kinds and in someexamples, portions of the channel may also may be topped with structuresthat act as antenna. In some other examples, the channel may be layeredwith different layers of materials, some of the layer may contain andinsulate metallic wires, optical fiber and other such active components.

Referring to FIG. 14B, an advanced roadway 1410 in conjunction with anAddibot 1430 is depicted. In some examples, an advanced roadway may havebeen formed with use of Addibots in a manner as described. The roadwaymay be formed with embedded sensors, antennas or other devices forfacilitating communication 1431 between an Addibot 1430 and the advancedroadway 1410. Within the advanced roadway 1410 may be communicationdevices 1432 that may be buried within the roadway, the shoulder or theside of the roadway or be upon these locations. In some examples, theremay be communication devices on roadway poles, signs and the like. Thecommunication 1431 may comprise wireless communication and may involveradio frequency, infrared frequency, optical frequency or other forms ofwireless communication. In some examples, the advanced roadway may beformed with embedded fibers 1435 formed of conductive materials oroptical fiber. The embedded fibers 1435 may also be considered wires.There may be connection of wires 1438 to power sources along theroadway. The power sources may be standalone sources such as solarpanels 1437 or be connected to power transmission grids 1439.

Communication signals may be routed through the advanced roadway andshoulders of roadways as depicted in FIG. 14B. In some examples, thecommunication signals may be routed out of the roadway to a wirelesstransmitter 1433 located along the roadway. In some examples, signalsmay be transmitted from one wireless transmitter 1433 to anothertransmitter 1436. A combination of transmission through conduits in theroadbed and to roadside transmitters may be used to transmit signals ofvarious kinds. In some examples the signals may relate to the movementof traffic along the roadway. The signals may also relate to conditionsalong the roadway as detected by sensors or traffic itself. In otherexamples the signals may involve communication signals unrelated to thetraffic and may be standard communications that are routed alongroadways. The signals from the roadside communication transmitters suchas wireless transmitter 1433 may be routed to neighboring structures1434 such as residences or businesses. The transmissions in someexamples may comprise standard internet communication transmissions, orin other examples the signals may relate to traffic flow along theroadway. Autonomous vehicles may use the various communications andsensor pathways as part of technological support of the traffic flow.Signals from traffic may be routed from vehicle to vehicle with thesupport of the roadway communication system. And, signals from trafficmay be routed along wireless pathways to internet connections to centralcontrollers for traffic flow that may be located at off road sites suchas neighboring structures 1434. The internet connections may be used totransmit signals from and to remote control systems.

In an example related to FIG. 14B, the communication and control systemsmay be used to control repair of advanced roadways. Addibot 1430, may beguided to regions that need repair of various types. The need for repairmay be detected in various manners such as for example sensors or imagecapture devices on traffic vehicles, control information provided byhuman inspectors or roadway users or the like. In another use of thecommunication infrastructure of the exemplary advanced roadway system,the Addibot can also receive location information from the informationand communication systems of the advanced roadway.

Referring to FIG. 15, an illustration of exemplary defects in a roadway1510 is illustrated. Cracks 1520 of various types may occur in a roadwaysurface. There may be numerous causes for the formation of cracks; butafter a crack forms it can grow and generate more serious defects aswater may begin to infiltrate the crack. A more serious defect may berepresented by pothole 1530. Here too, there may be numerous causes forthe formation of potholes. However, potholes will also tend to grow overtime if they are not repaired. For illustrative purposes, pothole 1530is illustrated with a level of water within the pothole. These exemplarytypes of defects and others may be treated by the utilization of anAddibot.

An Addibot, may be guided to a defect through communication of locationinformation. In other examples, an Addibot may analyze a road surface todetect the presence of cracks or potholes in a non-limiting example.Teams of Addibots may survey roads and repair the defects that arefound. Examples have been provided for the repair of potholes inconjunction with advanced roadways, it may be apparent that Addibots maybe used in similar manners for repair of such features on genericroadways of various types.

The exemplary Addibot as has be described earlier in the presentdisclosure may be used to perform a process of repair, and referring toFIG. 16A, a repair on a pothole 1600 may be illustrated. An exemplarystep for drying the pothole 1605 defect may start with a vacuum processor the addition of a drying agent followed by its removal. Next fillingmaterial may be added to the pothole. In an example, a compositematerial 1615 of filler and adhesive/sealing material may be added inaddition step 1610.

In another example of an addition step 1620, a layer of filler material1625 such as stone may be added as an example. An addition step 1630 mayadd a layer of adhesive and sealing material 1635 upon the layerdeposited in the addition step 1620. In some examples, the addition step1620 and addition step 1630 may be performed and then repeated insequence numerous times until the pothole 1600 is filled to anappropriate level. In some examples, the appropriate fill level may beto the top of the pothole 1600 to be level with the surrounding roadway.In other examples the appropriate fill level may be above the level ofthe surrounding roadway.

In some examples, the filed pothole 1600 may be further processed byprocessing after filling 1640. The processing after filling may includerolling or other high pressure treatments to consolidate the filledmaterial. In other examples, treatments with polymerizing treatmentssuch as exposure to Ultra-Violet light(UV) may be performed to initiatepolymerization reactions with appropriate polymerizable material if itwas included in the adding of a layer of adhesive or sealing materialsteps. In some examples, a cooling treatment 1645 may be performed ifthe filler material and adhesive and sealing material are added hot orgenerate heat in their polymerization processing. The cooling treatment1645 may be performed to cool at least a surface layer of the filledmaterial so that traffic may be allowed to run on the repaired roadway.

The exemplary Addibot as has be described earlier in the presentdisclosure may be used to perform a process of repair, and referring toFIG. 16B, a repair of cracks 1650 may be illustrated. An exemplary stepfor cleaning the cracks 1655 may start with a cleaning with pressurizedair as a non-limiting example. Next filling material may be added to thecrack. In an example, a sealing agent 1665 may be added in addition step1660. The Addibot may position a component to perform the addition step1660.

In another example of an addition step 1670, an array of components maydeposit multiple locations of droplets 1675 of sealing material. Thepattern of the multiple droplets may be controlled by a controllerwithin the Addibot. As the Addibot moves over the roadway it maydispense sealing material at appropriate locations based on cracklocation. In some examples, the steps at 1660 and 1670 may be performedand then repeated in sequence numerous times until the crack 1650 at aparticular location is filled to an appropriate level. In some examples,the appropriate fill level may be to the top of the crack 1650 to belevel with the surrounding roadway. In other examples the appropriatefile level may be above the level of the surrounding roadway.

In some examples, the filed crack 1650 may be further processed byprocessing after filling 1680. The processing after filling may includerolling or other high pressure treatments to consolidate the filledmaterial. In other examples, treatments with polymerizing treatmentssuch as exposure to Ultra-Violet light (UV) may be performed to initiatepolymerization reactions with appropriate polymerizable material if itwas included in the adding of sealing material steps. In some examples,a cooling treatment 1685 may be performed if the filler material andadhesive and sealing material are added hot or generate heat in theirpolymerization processing. The cooling treatment 1685 may be performedto cool at least a surface layer of the filled material so that trafficmay be allowed to run on the repaired roadway. Examples have beenprovided for the repair of cracks in conjunction with discussion ofadvanced roadway, it may be apparent that Addibots may be used insimilar manners for repair of such features on generic roadways ofvarious types.

The interaction of an Addibot and an advanced roadway may be useful inboth the respect of creating the advanced roadway and in repairing it.The resulting advanced roadway may also be useful for advanced vehicleoperation as well. In a non-limiting example, driverless cars mayreceive communication, location information, intra-vehicle informationsharing, guidance related information and the like through operation ofthe components of the advanced roadway as described herein. Referring toFIG. 17, an advanced roadway 1710 in conjunction with a vehicle 1730 isdepicted. In some examples, an advanced roadway may have been formedwith use of Addibots in a manner as described. The roadway may be formedwith embedded sensors, antennas or other devices for facilitatingcommunication 1731 between a vehicle 1730 and the advanced roadway 1710.Within the advanced roadway 1710 may be communication devices 1732 thatmay be buried within the roadway, the shoulder or the side of theroadway or be upon these locations. In some examples, there may becommunication devices on roadway poles, signs and the like. Thecommunication 1731 may comprise wireless communication and may involveradio frequency, infrared frequency, optical frequency or other forms ofwireless communication. In some examples, the advanced roadway may beformed with embedded fibers 1735 formed of conductive materials oroptical fiber. The embedded fibers 1735 may also be considered wires.There may be connection of wires 1738 to power sources along theroadway. The power sources may be standalone sources such as solarpanels 1737 or be connected to power transmission grids 1739.

Communication signals may be routed through the advanced roadway andshoulders of roadways as depicted in FIG. 17. In some examples, thecommunication signals may be routed out of the roadway to wirelesstransmitter 1733 located along the roadway. In some examples, signalsmay be transmitted from one wireless transmitter 1733 to anothertransmitter 1736. A combination of transmission through conduits in theroadbed and to roadside transmitters may be used to transmit signals ofvarious kinds. In some examples the signals may relate to the movementof traffic along the roadway. The signals may also relate to conditionsalong the roadway as detected by sensors or traffic itself. In otherexamples the signals may involve communication signals unrelated to thetraffic and may be standard communications that are routed alongroadways. The signals from the roadside communication transmitters suchas wireless transmitter 1733 may be routed to neighboring structures1734 such as residences or businesses. The transmissions in someexamples may comprise standard internet communication transmissions, orin other examples the signals may relate to traffic flow along theroadway. Autonomous vehicles may use the various communications andsensor pathways as part of technological support of the traffic flow.Signals from traffic may be routed from vehicle to vehicle with thesupport of the roadway communication system. And, signals from trafficmay be routed along wireless pathways to internet connections to centralcontrollers for traffic flow that may be located at off road sites suchas neighboring structures 1734. The internet connections may be used totransmit signals from and to remote control systems. In some examples,the communication infrastructure of the advanced roadway system may beutilized for data communications that are not related to traffic, repairor other aspects of the roadway itself such as internet connectivity forresidential and commercial operations within the vicinity of roadways.

Methods

There may be numerous methods of utilizing an Addibot, manufacturing anAddibot or creating a product with an Addibot. Referring again to FIG. 8and now to FIG. 18, an exemplary set of method steps that may becommonly utilized in numerous examples of Addibots are displayed. Thesteps are displayed in a flow chart for example. The steps may flexiblybe used or not used and the order of the steps may be changed within thescope of the inventive art of Addibots.

For these examples we can consider the methods in referring to FIG. 8,at 810, an Addibot of a particular type may be obtained by a user. Next,at step 820 the user may transmit a control signal to the Addibot. Thetransmitting may involve numerous means including a wirelesstransmission, a wired transmission or a transmission involving aphysical interaction such as pushing a switch or a display panel of anAddibot. The initiation signal may cause a variety of responses that areproximately caused by the initiation even if further interaction withthe user is or is not required or if the Addibot will flexibly respondto its environment or programming thereafter.

At 830, in some examples the Addibot may perform an orientation step.This step may assess one or more of determining a spatial location in aspatial coordinate system and may also assess movement and direction ofmovement or potential movement in a spatial coordinate system.

At step 840, in some examples the Addibot may perform a metrologyprocess on a region of a surface. In other examples at step 840 anapparatus external to an Addibot may perform a metrology process on aregion of a surface and may communicate information to an Addibotrelated to the metrology or related to the processing of the metrologydata 850 in some form. In some examples, these metrology steps mayinvolve the measurement of surface topography in such a manner as toidentify cracks and holes or potholes in the surface of a roadway.

Additionally, at 850, in some examples the Addibot may process theresult of the metrology by means of a processor. The processor may insome examples identify the presence of a crack or other defect,determine a need for such a feature to be filled or otherwise haveaction performed on it, and then establish the location information forthe feature detected.

At step 860, in some examples the Addibot will utilize the informationthat it has received in various manners about the surface and anydesired model that results from this information and based on a digitalmodel provide controlling signals to the additive manufacturing system.The controlling signals may cause a component to release material ontothe surface at a prescribed time as the component becomes located over adesired location.

At step 870, in some examples, the Addibot will deposit a first layer ofmaterial on a surface. In some examples, the first layer of materialwill be comprised of adhesives or sealers. In some other examples, thefirst layer of material may be comprised of a mixture of aggregate orsmall solids and an adhesive or sealing agent. In still furtherexamples, the adhesive or sealing agent may be further processed byexposure to an energy source such as a UV light exposure to initial apolymerization reaction in the material.

At step 835, there may be a loop process that occurs in some examplesand under some situations that may cause the Addibot to return to step830 and continue processing. In an alternative example, in someexamples, as shown at step 845 a loop process may occur that may causethe Addibot to return to step 840 and continue processing.

At step 880, a step may occur where the Addibot is moved from a firstlocation to a second location. In some examples, a characteristic ofthis movement is that as part of the Addibot moving the additivemanufacturing system as a whole moves from a first location to a secondlocation even if portions of the additive manufacturing system couldmove some or all of the printing head or other additive element to thesame second location without a movement of the Addibot.

At step 890, the Addibot may deposit at the second location a secondlayer of material. The nature of the second deposit may comprise adifferent material, or a same material. The nature of the second depositmay comprise a different physical characteristic such as thickness orthe same characteristic as a first deposit. The second deposit may becontiguous with a first deposit but be located at a second location andbe considered a second deposit, by the very nature of being at a secondlocation.

Referring to FIG. 18, an Addibot of a particular type may be obtained1810 by a user. Next, at step 1820 the user may transmit a controlsignal to the Addibot. The transmitting may involve numerous meansincluding a wireless transmission, a wired transmission or atransmission involving a physical interaction such as pushing a switchor a display panel of an Addibot. The initiation signal may cause avariety of responses that are proximately caused by the initiation evenif further interaction with the user is or is not required or if theAddibot will flexibly respond to its environment or programmingthereafter.

At 1830, in some examples the Addibot may perform an orientation step.This step may assess one or more of determining a spatial location in aspatial coordinate system and may also assess movement and direction ofmovement or potential movement in a spatial coordinate system.

At 1840, in some examples the Addibot may perform a metrology process ona region of a surface. In other examples at 1840 an apparatus externalto an Addibot may perform a metrology process on a region of a surfaceand may communicate information to an Addibot related to the metrologyor related to the processing of the metrology data in some form 1850. Insome examples, these metrology steps may involve the measurement ofsurface topography in such a manner as to allow for the adjustment ofthe level of a forming mold as it is placed to interact with thesurface.

Additionally, at 1850, in some examples the Addibot may process theresult of the metrology by means of a processor. The processor may insome examples identify the level of the surface. In other examples theprocessor may identify the presence of a crack or other defect,determine a need for such a feature to be filled or otherwise haveaction performed on it, and then establish the location information forthe feature detected. In some examples, the detection of a defect maycause the Addibot to send a signal and wait for a user to interact withthe Addibot for additional controls.

At step 1860, in some examples the Addibot will utilize the informationthat it has received in various manners about the surface and anydesired model that results from this information and based on a digitalmodel provide controlling signals to the additive manufacturing system.The controlling signals may cause the Addibot to adjust the level ofcomponents within the Addibot; or the level of the Addibot frame itself.

At step 1870, in some examples, the Addibot may create a first structureby extruding material into a forming mold. In some examples, the firstlayer of material will be comprised of thermoplastics or other extrusionmaterials. In some examples, the Addibot may fill a portion of theresulting formed structure with wall forming materials such as cement.In other examples, the Addibot may signal the completion of a firststructure formation and another device or another Addibot may add wallforming materials to the thus formed structure.

At step 1835, there may be a loop process that occurs in some examplesand under some situations that may cause the Addibot to return to step1830 and continue processing. In an alternative example, in someexamples, as shown at step 1845 a loop process may occur that may causethe Addibot to return to step 1840 and continue processing.

At step 1880, a step may occur where the Addibot is moved from a firstlocation to a second location. In some examples, a characteristic ofthis movement is that as part of the Addibot moving the additivemanufacturing system as a whole moves from a first location to a secondlocation even if portions of the additive manufacturing system couldmove some or all of the printing head or other additive element to thesame second location without a movement of the Addibot. Forming moldpieces that may be present in the Addibot may be moved verticallyupwards and downwards in the process of readying the Addibot formovement and then preparing the Addibot for a next processing step.

At step 1890, the Addibot may create a second structure by extrudingmaterial into a forming mold at the second location. The nature of thesecond structure formed may comprise a different material, or a samematerial. The nature of the second structure formed may comprise adifferent physical characteristic such as thickness or the samecharacteristic as a first deposit. The second structure formed may becontiguous with a first structure formed but be located at a secondlocation and be considered a second structure, by the very nature ofbeing at a second location.

CONCLUSION

A number of examples of the present disclosure have been described.While this specification contains many specific implementation details,they should not be construed as limitations on the scope of anyinventions or of what may be claimed, but rather as descriptions offeatures specific to particular examples of the present disclosure.

Certain features that are described in this specification in the contextof separate examples can also be implemented in combination in a singleembodiment. Conversely, various features that are described in thecontext of a single embodiment can also be implemented in combination inmultiple examples separately or in any suitable sub-combination.Moreover, although features may be described above as acting in certaincombinations and even initially claimed as such, one or more featuresfrom a claimed combination can in some cases be excised from thecombination, and the claimed combination may be directed to asub-combination or variation of a sub-combination.

Similarly, while operations are depicted in the drawings in a particularorder, this should not be understood as requiring that such operationsbe performed in the particular order shown or in sequential order, orthat all illustrated operations be performed, to achieve desirableresults. In certain circumstances, multitasking and parallel processingmay be advantageous.

Moreover, the separation of various system components in the examplesdescribed above should not be understood as requiring such separation inall examples, and it should be understood that the described componentsand systems can generally be integrated together in a single product orpackaged into multiple products.

In addition, the processes depicted in the accompanying figures do notnecessarily require the particular order shown, or sequential order, toachieve desirable results. In certain implementations, multitasking andparallel processing may be advantageous. While the disclosure has beendescribed in conjunction with specific examples, it is evident that manyalternatives, modifications and variations will be apparent to thoseskilled in the art in light of the foregoing description. Accordingly,this description is intended to embrace all such alternatives,modifications and variations as fall within its spirit and scope.Certain features that are described in this specification in the contextof separate embodiments can also be implemented in combination in asingle embodiment. Conversely, various features that are described inthe context of a single embodiment can also be implemented incombination in multiple embodiments separately or in any suitablesub-combination.

Similarly, while operations are depicted in the drawings in a particularorder, this should not be understood as requiring that such operationsbe performed in the particular order shown or in sequential order, orthat all illustrated operations be performed, to achieve desirableresults. In certain circumstances, multitasking and parallel processingmay be advantageous.

Moreover, the separation of various system components in the embodimentsdescribed above should not be understood as requiring such separation inall embodiments. Examples of Addibots may include all system componentsor a subset of components and may act in multiples to perform variousfunctions.

The invention claimed is:
 1. A method of forming a wall construction,the method comprising: obtaining at least a first mobile additivemanufacturing apparatus, wherein the first mobile additive manufacturingapparatus comprises: a controller capable of executing algorithms andproviding control signals; a first additive manufacturing system todeposit a material or combination of materials in prescribed locationsacross a surface according to a first digital model processed by thecontroller, wherein the first additive manufacturing system comprises afirst molding form; a first drive system operative to transport thefirst mobile additive manufacturing system along the surface; a firstvision system, wherein the first vision system scans the surface andmeasures a topography of the surface, while the first mobile additivemanufacturing apparatus passes thereover; a first navigation system todetermine a location of the first mobile additive manufacturing systemand guide the first drive system; a first power system capable ofproviding power to operate at least the first drive system, firstnavigation system, first controller and first additive manufacturingsystem; a second digital model formed by measurement utilizing the firstvision system, wherein the second digital model is of a topography ofthe surface in a region proximate to the first mobile additivemanufacturing apparatus; a first material storage system capable tostore at least a first material to be supplied to the first additivemanufacturing system; and a first communication system capable oftransmitting signals outside the first mobile additive manufacturingapparatus and receiving signals originating from outside the firstmobile additive manufacturing apparatus, wherein the transmitted signalscomprise one or more of radiofrequency, infrared, optical or sound basedemissions; adjusting the first digital model based upon the seconddigital model, whereas the adjustment aligns the first digital model toa first processing location; extruding the first material into the firstmolding form; allowing the first material to solidify in the firstmolding form to form a first molded feature; removing the first moldingform from the solidified material; and moving to a second processingposition, wherein the moving is based upon the first digital model. 2.The method of forming a wall construction of claim 1 further comprising:obtaining at least a second mobile additive manufacturing apparatus,wherein the second mobile additive manufacturing apparatus comprises: asecond controller capable of executing algorithms and providing controlsignals; a second additive manufacturing system to deposit a material orcombination of materials in prescribed locations across a surfaceaccording to the first digital model processed by the controller,wherein the second additive manufacturing system comprises a secondmolding form; a second drive system operative to transport the secondmobile additive manufacturing system along the surface; a second visionsystem, wherein the second vision system scans the surface and measuresa topography of the surface, while the second mobile additivemanufacturing apparatus passes thereover; a second navigation system todetermine a location of the second mobile additive manufacturing systemand guide the second drive system; a second power system capable ofproviding power to operate at least the second drive system, secondnavigation system, second controller and second additive manufacturingsystem; a material storage system capable to store at least the firstmaterial to be supplied to the second additive manufacturing system; anda second communication system capable of transmitting signals outsidethe second mobile additive manufacturing apparatus and receiving signalsoriginating from outside the second mobile additive manufacturingapparatus, wherein the transmitted signals comprise one or more ofradiofrequency, infrared, optical or sound based emissions; moving thesecond mobile additive manufacturing apparatus to a third location,wherein the first digital model is used to direct the second mobileadditive manufacturing apparatus to the third location in a teamapproach; extruding the first material into the second molding form;allowing the first material to solidify in the second molding form toform a second molded feature; removing the second molding form from thesolidified material; and moving to a fourth processing position, whereinthe moving is based upon the first digital model.
 3. The method offorming a wall construction of claim 2 further comprising filling atleast a portion of the first molded feature with a second material andfilling at least a portion of the second molded feature with the secondmaterial.
 4. The method of forming a wall construction of claim 3wherein the second material comprises a polymer.
 5. The method offorming a wall construction of claim 3 wherein the second materialcomprises macadam.
 6. The method of forming a wall construction of claim3 wherein the second material comprises plaster.
 7. The method offorming a wall construction of claim 3 wherein the second materialcomprises a liquid.
 8. The method of forming a wall construction ofclaim 3 wherein the second material comprises concrete.
 9. The method offorming a wall construction of claim 8 wherein a non-filled portion ofthe first molded form forms a conduit through which at least a wire maypass.
 10. The method of forming a wall construction of claim 8 wherein anon-filled portion of the first molded form forms a duct.
 11. The methodof forming a wall construction of claim 2 further comprising: obtainingat least a third mobile additive manufacturing apparatus, wherein thethird mobile additive manufacturing apparatus comprises: a thirdcontroller capable of executing algorithms and providing controlsignals; a third additive manufacturing system to deposit a material orcombination of materials in prescribed locations across a surfaceaccording to the first digital model processed by the third controller,wherein the third additive manufacturing system comprises an extrusiondevice, wherein the extrusion device extrudes a second material; a thirddrive system operative to transport the third mobile additivemanufacturing system along the surface; a third vision system, whereinthe third vision system scans the surface and measures a topography ofthe surface, while the third mobile additive manufacturing apparatuspasses thereover; a third navigation system to determine a location ofthe third mobile additive manufacturing system and guide the third drivesystem; a third power system capable of providing power to operate atleast the third drive system, third navigation system, third controllerand third additive manufacturing system; a third material storage systemcapable to store at least the second material to be supplied to thethird additive manufacturing system; and a third communication systemcapable of transmitting signals outside the third mobile additivemanufacturing apparatus and receiving signals originating from outsidethe third mobile additive manufacturing apparatus, wherein thetransmitted signals comprise one or more of radiofrequency, infrared,optical or sound based emissions; moving the third mobile additivemanufacturing apparatus to a fifth location, wherein the first digitalmodel directs the third mobile additive manufacturing apparatus to thefifth location in a team approach and wherein the fifth locationpositions the third mobile additive manufacturing apparatus to extrudethe second material into an open internal portion of the first moldingform; extruding the second material into the first molding form; andmoving the third mobile additive manufacturing apparatus to a sixthprocessing position, wherein the moving is based upon the first digitalmodel.
 12. The method of forming a wall construction of claim 11 whereinthe second material comprises a polymer.
 13. The method of forming awall construction of claim 11 wherein the second material comprisesmacadam.
 14. The method of forming a wall construction of claim 11wherein the second material comprises plaster.
 15. The method of forminga wall construction of claim 11 wherein the second material comprises aliquid.
 16. The method of forming a wall construction of claim 11wherein the second material comprises concrete.
 17. A method of forminga wall construction, the method comprising: obtaining at least a firstmobile additive manufacturing apparatus, wherein the first mobileadditive manufacturing apparatus comprises: a first controller capableof executing algorithms and providing control signals; a first additivemanufacturing system to deposit a material or combination of materialsin prescribed locations across a surface according to a first digitalmodel processed by the first controller, wherein the first additivemanufacturing system comprises a first molding form; a first drivesystem operative to transport the first mobile additive manufacturingsystem along the surface; a first vision system, wherein the firstvision system scans the surface and measures a topography of thesurface, while the first mobile additive manufacturing apparatus passesthereover; a first navigation system to determine a location of thefirst mobile additive manufacturing system and guide the first drivesystem; and a first power system capable of providing power to operateat least the first drive system, first navigation system, firstcontroller and first additive manufacturing system; extruding a firstmaterial into the first molding form; allowing the first material tosolidify in the first molding form to form a first molded feature;removing the first molding form from the solidified material; and movingto a second processing position.
 18. The method of forming a wallconstruction of claim 17 further comprising: obtaining at least a secondmobile additive manufacturing apparatus, wherein the second mobileadditive manufacturing apparatus comprises: a second controller capableof executing algorithms and providing control signals; a second additivemanufacturing system to deposit a material or combination of materialsin prescribed locations across a surface according to the first digitalmodel processed by the second controller, wherein the second additivemanufacturing system comprises a second molding form; a second drivesystem operative to transport the second mobile additive manufacturingsystem along the surface; a second vision system, wherein the secondvision system scans the surface and measures a topography of thesurface, while the second mobile additive manufacturing apparatus passesthereover; a second navigation system to determine a location of thesecond mobile additive manufacturing system and guide the second drivesystem; and a second power system capable of providing power to operateat least the second drive system, second navigation system, secondcontroller and second additive manufacturing system; moving the secondmobile additive manufacturing apparatus to a third location in a teamapproach; extruding the first material into the second molding form;allowing the first material to solidify in the second molding form toform a second molded feature; removing the second molding form from thesolidified material; and moving to a fourth processing position.
 19. Themethod of forming a wall construction of claim 18 further comprising:obtaining at least a third mobile additive manufacturing apparatus,wherein the third mobile additive manufacturing apparatus comprises: athird controller capable of executing algorithms and providing controlsignals; a third additive manufacturing system to deposit a material orcombination of materials in prescribed locations across a surfaceaccording to the first digital model processed by the third controller,wherein the third additive manufacturing system comprises an extrusiondevice, wherein the extrusion device extrudes a second material; a thirddrive system operative to transport the third mobile additivemanufacturing system along the surface; a third vision system, whereinthe third vision system scans the surface and measures a topography ofthe surface, while the third mobile additive manufacturing apparatuspasses thereover; a third navigation system to determine a location ofthe third mobile additive manufacturing system and guide the third drivesystem; and a third power system capable of providing power to operateat least the third drive system, third navigation system, thirdcontroller and third additive manufacturing system; moving the thirdmobile additive manufacturing apparatus to a fifth location, wherein thefifth location positions the third mobile additive manufacturingapparatus to extrude the second material into an open internal portionof the first molding form; extruding the second material into the firstmolding form; and moving the third mobile additive manufacturingapparatus to a sixth processing position.
 20. The method of forming awall construction of claim 19 wherein the moving of the first, secondand third mobile additive manufacturing apparatus is based upon thefirst digital model.